lpg caverns storage
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ROCK CAVERNS FOR LNG
Kamal Deshapriya
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Going Underground
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70 yrs History….
Up to second world war.. First solution mined cavern in the
Canada reportedly conceived in early 1940
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Underground Caverns in France
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Geogaz-Lavera- France
60000T storage facility for commercial propane -1971
Storage facility for butane 85000T - 1984
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Geosel- Manosquesalt leached caverns
7.5 million m3 capacity- 1969
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Gas Caverns in US,48 regions…
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LNG storage caverns in Ontario, Canada
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Sydney LPG Cavern
First natural underground storage facility in Australia
135m under port botany in Sydney
65000 MT of LPG storage
Completed in 1999
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Other Caverns…
Yeosu Terminal-1983 First Rock Cavern in Korea
Incheon LPG Cavern –Korea Sarajeh in Iran- 2009, 16 billion tons
of LNG Shurijeh in Iran- 2009, 20 billion
cubic meters of LNG Qingdao facility China- 117000 T LPG
capacity
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Other Caverns in South Asia…
Source: Report of Kim, Tae Moon, Advisor, The Korean Institute of Gas, Republic of Korea
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Visakhapatnam -India
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Visakhapatnam -India
Visakhapatnam (Andra Pradesh)-2007 60000 MT LPG capacity for largest LPG terminal
in india Owners are South Asia LPG company and
Hindustan Petroleum Corporation Design and consultancy by GEOSTOCK France▪ Process▪ Geological▪ Hydro geological▪ Geo mechanical design
LARSEN & TOURBO Indian construction company
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Visakhapatnam India
Suitable sub soil stratum for cavern Hard gneissic rock 162 m below in sea level Two main caverns 19m in height , 20
m in width and 160 m in length connected with small galleries
Receive large tankers Re-exporting potential for south east
Asia
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Visakhapatnam India
Construction stages Diaphragm wall excavated from surface
to 20m in sandy and unconsolidated rock
Shaft sinking in rock from -30m to -162m Water curtain gallery at boreholes at -
147 m Storage cavern excavation Installation of castings and tubing's in
shafts Construction of concrete plug above the
cavern
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Visakhapatnam India
Above ground facilities To receive largest size LPG vessels
( 40000T) LPG loading arms Chilling and booster pumps Seawater heat exchanger and pump
house Mixing skid and a vapor ejector
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Gas Cavern Storing
Technology
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Example of Rock Cavern constructed using road headers for top heading & blasting for benching followed by trimming by road headers. Cross section is 85 sq m
Source : Geostock
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Flow of LPG Cavern Storage
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Cavern Techniques
Mined Caverns Lined Mined Caverns Salt-leached Cavern Porous Media
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Mined Caverns….
Access Ramp (AR)
Upper Connection (UC)
Intermediate connection (IC)
Upper Shaft Connection (USC)
Access Shaft (AS)
Operation Shaft (OS)
Lower Shaft Connection
(LSC)
Water Gallery – Operation Shaft
Connection (WOC)
Water Gallery – Access Shaft
Connection (WAC)
Water Curtain Gallery (WCG
Sump which houses the submersible
pumps
Lower connection (LC)
22The finished rock cavern for LPG at
Visakhapatnam
Example of an Underground Unlined Rock Cavern
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Salt Dome
Salt Leached Caverns
Borehole
Water injection
Brine
Several hundred meters Tens of
meters
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Aquifers
Impermeable stratum
Porous & Permeable Geological formation
Hydrocarbon Storage
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Disused Mines
Water table
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Caverns using vertical shafts for access…
Access Ramp (AR)
Upper Connection (UC)
Intermediate connection (IC)
Upper Shaft Connection (USC)
Access Shaft (AS) Operation Shaft
(OS)
Lower Shaft Connection
(LSC)
Water Gallery – Operation Shaft
Connection (WOC)
Water Gallery – Access Shaft
Connection (WAC)
Water Curtain Gallery (WCG
Sump which houses the submersible
pumps
Lower connection (LC)
27Source : Geostock
Example of cavern using a ramp for Access
Inclined Ramp
Water Curtain
Main Storage Galleries
Operation Shafts
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Rock Caverns
Depth varies from 70m to 200m from ground..
Size vary according to the geological condition
There are two types Mined caverns Mined Lined caverns▪ For Poor geological condition▪ Plastic or metal lining with concrete plaster
mine surface
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Suitable Rocks for Caverns Igneous
Granite, diorite Metamorphic
Gneisis Schists hornfels
Sedimentary rocks Sandstone Limestone Chalk shale
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Tightness Principle
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Mined Caverns
Cavity created in rock using mining techniques
Consist one or more galleries excavated in rock
Unlined Caverns, prevent product escape by hydraulic containment principle
Rock must be hard enough to cavern to be stable
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Cavern Stability
GOOD GEOLOGYMEDIUM TO BAD GEOLOGY
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Lined Rock CavernsThese types of storage facilities can be used for small or medium sized caverns. The lining can be steel or plastics. In the depths are large the linings have to be designed to counter the hydrostatic pressure or the can get
Steel or plastic lining
Over breaks and rock falls
Over breaks as shown can slow down progress to a large extent. Also a major safety issue.
Method of addressing poor rock conditions
To ensure there is good stability of the cavern, rock bolts need to be installed and shortcrete applied. Poorer the rock strata, larger is the support requirement.
Rock bolts
Shotcrete
Example of Poor Rock Conditions
Large number of cracks and fissures in the rock could lead to large over breaks .and excessive supports
Example of a water bearing zone
Water bearing zones could result in large water ingress if pre-grouting is not resorted to. The time taken up by grouting could delay excavation.
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Pre-Grouting in excessive water bearing zones
Pre-Grouting involves drilling a number of holes on the face and pumping cement paste under pressure into them till sealing is achieved.
High permeability and water bearing strata could result in higher grouting and slow excavation progress.
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Mined Lined Caverns….
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Gas Cavern Construction
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LPG Caverns to be constructed….
Access Ramp (AR)
Upper Connection (UC)
Intermediate connection (IC)
Upper Shaft Connection (USC)
Access Shaft (AS)
Operation Shaft (OS)
Lower Shaft Connection
(LSC)
Water Gallery – Operation Shaft
Connection (WOC)
Water Gallery – Access Shaft
Connection (WAC)
Water Curtain Gallery (WCG
Sump which houses the submersible
pumps
Lower connection (LC)
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Process Steps…
Pre- Feasibility Feasibility study and site
investigation Project decision Complimentary site investigation Basic engineering Design Permitting, Project financing Contract award Construction First LPG import
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Codes of Practices
CAN/CSA Z341 Series -98 Storage of Hydrocarbons in Underground Formations
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View of Construction Site- VishakaPatnam
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Shaft excavation
Excavation Using Drill & Blast (For Hard Rock) Two Boom Jumbo (Used for drilling in hard rock)
Excavation using Road Headers (For Soft Rock) Road Headers (Used in case of soft to medium hard rock
Limestone, Chalk etc)
Equipment lowering through Shaft
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Drilling & Blasting Method of Excavation
Holes are charged with explosives after drilling and controlled blasting carried out
Jumbo used for drilling holes in rock
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Pull
Drilling & Blasting Method of Excavation
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Drilling in water gallery
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Drilling of bench 1
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Drilling of top Heading
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Example of Rock Cavern constructed using road headers for top heading & blasting for benching followed by trimming by road headers. Cross section is 85 sq m
Source : Geostock
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Operating Shaft
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Concrete plug in operation shaft
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Surface Installations
Product injection and withdrawal Gas recirculation compressor Seepage water degassing before
disposal (Water treatment plant) Refrigeration system Gas heating system
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Surface Installations
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Sea Water Heat Exchanger
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Sea Water Intake
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Caverns on Surface Storages..
62Storage capacity
Cost
/ m
3 o
f st
ora
ge
Caverns in less favorable geological
conditions
Caverns in favorable geological conditions
Lower Marginal Costs – For larger volumes
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Caverns Vs. Others in 2000…
Volume Cost in USD/ Cu.m
Leached Salt Caverns
100-200
Rock Mined Caverns
10, 000 800-1200
50,000 340-580
100,000 300-500
500,000 180-280
Mounded Storage
2000-4000 800-1600
Pressurized Spheres
600-800
Refrigerated Tanks
600-800Source: Report of Kim, Tae Moon, Advisor, The Korean Institute of Gas, Republic of Korea
For All Volumes
For All Volumes
For All Volumes
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Advantages of going underground
Beyond certain capacities, the capital cost per ton of storage is low.
Product is located at a depth and is fully isolated.
External Fires will not affect Storage
Maximum security. Safety hazards on account of sabotage, storms, earthquakes and explosions are minimized.
Surface land requirement is low
Caverns by their very nature require very low maintenance.
Environment benefits. The rock debris generated can be used for infrastructure development.
Longer life
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Disadvantages…
Time consuming construction Continuous monitoring required with
sufficient staff for operation Moisture contamination Critical, expensive temperature
control Inefficient heating and cooling Gas Cushion and working volume
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LPG Caverns for Hambanthota….
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Tips from Geology Of Sri Lanka..
Sri Lanka is Part of a “Shield” area which includes Peninsular India
“Iland along with peninsular India is part of a segment of the earth crust made up of an ancient crystalline complex sufficiently rigid to withstand crustal movements and thus has remained in inflexible land mass.”
Source: Science Education Series, No 17, by L.J.D. Fernando. NERD, 1986
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Special Credits for “Geostock”, France
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